Aluminum cup
The various embodiments described herein include aluminum cups and method and materials to form aluminum cups. In one aspect, an aluminum cup includes a cup side wall including an aluminum foil layer, a first polymer layer, and a second polymer layer. The first perpendicular edge of the cup side wall can be heat-bonded to the second perpendicular edge of the cup side wall, bonding the first polymer layer to the second polymer layer.
1 . An aluminum cup comprising:
a common aluminum material comprising:
an aluminum foil layer, comprising a common foil thickness of between 80 to 180 microns;
a first polymer layer disposed on a first surface of the aluminum foil layer; and
a second polymer layer disposed on a second surface of the aluminum foil layer opposite the first surface;
a cup side wall formed from the common aluminum material, the cup side wall comprising:
a first perpendicular edge; and
a second perpendicular edge,
wherein the first perpendicular edge of the cup side wall is bonded to the second perpendicular edge of the cup side wall to bond the first polymer layer to the second polymer layer, to have a frustoconical shape; and
a cup bottom formed from the common aluminum material, wherein the cup side wall is coupled to the cup bottom and the cup side wall and the cup bottom have the same common foil thickness.
2 . The aluminum cup of claim 1 , wherein the frustoconical shape comprises a constant taper.
3 . The aluminum cup of claim 1 , wherein the first polymer layer of the cup side wall is disposed on a portion of the first surface adjacent to the first perpendicular edge of the cup side wall.
4 . The aluminum cup of claim 1 , wherein the second polymer layer of the cup side wall is disposed on a portion of the second surface adjacent to the second perpendicular edge of the cup side wall.
5 . The aluminum cup of claim 1 , further comprising a rolled lip at an upper edge of the cup side wall.
6 . The aluminum cup of claim 1 ,
wherein the cup side wall is bonded to the cup bottom to bond the first polymer layer of the cup side wall to the first polymer layer of the cup bottom.
7 . The aluminum cup of claim 1 , the first polymer layer of the common aluminum material comprising a first polymer thickness of between 5 to 60 microns, and the second polymer layer of the common aluminum material comprising a second polymer thickness of between 5 to 60 microns.
8 . The aluminum cup of claim 1 , wherein the frustoconical shape has a taper angle between about 3 degrees and about 12 degrees.
9 . The aluminum cup of claim 8 , wherein the taper angle of the frustoconical shape minimizes tearing of the cup side wall.
10 . An aluminum cup comprising:
a common aluminum material comprising:
an aluminum foil layer, comprising a common foil thickness of between 80 to 180 microns; and
a first polymer layer disposed on a first surface of the aluminum foil layer;
a cup side wall formed from the common aluminum material, the cup side wall; and
a cup bottom formed from the common aluminum material,
wherein the cup side wall is bonded to the cup bottom to bond the first polymer layer of the cup side wall to the first polymer layer of the cup bottom, the cup side wall forms a frustoconical shape, and the cup side wall and the cup bottom have the same common foil thickness.
11 . The aluminum cup of claim 10 , wherein the cup bottom has a circular profile.
12 . The aluminum cup of claim 10 , wherein the common aluminum material further comprises a second polymer layer disposed on a second surface of the aluminum foil layer opposite the first surface.
13 . The aluminum cup of claim 12 , the first polymer layer of the common aluminum material comprising a first polymer bottom thickness of between 5 to 60 microns, and the second polymer layer of the common aluminum material comprising a second polymer bottom thickness of between 5 to 60 microns.
14 . The aluminum cup of claim 10 , wherein a first perpendicular edge of the cup side wall is bonded to a second perpendicular edge of the cup side wall.
15 . The aluminum cup of claim 10 , further comprising a rolled lip at an upper edge of the cup side wall.
16 . The aluminum cup of claim 10 , wherein the frustoconical shape has a taper angle between about 3 degrees and about 12 degrees.
17 . The aluminum cup of claim 16 , wherein the taper angle of the frustoconical shape minimizes tearing of the cup side wall.
18 . An aluminum cup comprising:
a common aluminum material comprising:
an aluminum foil layer, comprising a common foil thickness of between 80 to 180 microns;
a first polymer layer disposed on a first surface of the aluminum foil layer; and
a second polymer layer disposed on a second surface of the aluminum foil layer opposite the first surface;
a cup side wall formed from the common aluminum material,
wherein the cup side wall forms a frustoconical shape; and
a cup bottom formed from the common aluminum material, wherein the cup side wall is coupled to the cup bottom and the cup side wall and the cup bottom have the same common foil thickness.
19 . The aluminum cup of claim 18 , wherein the first polymer layer of the cup side wall is disposed in an inner portion of the frustoconical shape.
20 . The aluminum cup of claim 18 , wherein the second polymer layer of the cup side wall is disposed on an outer portion of the frustoconical shape.
21 . The aluminum cup of claim 18 , further comprising a rolled lip at an upper edge of the cup side wall.
22 . The aluminum cup of claim 18 , wherein the cup side wall is bonded to the cup bottom to bond the first polymer layer of the cup side wall to the first polymer layer of the cup bottom.
23 . The aluminum cup of claim 18 , the common aluminum material comprising the first polymer layer comprising a first polymer thickness of between 5 to 60 microns, and the second polymer layer comprising a second polymer thickness of between 5 to 60 microns.
24 . The aluminum cup of claim 18 , wherein the frustoconical shape has a taper angle between about 3 degrees and about 12 degrees.
25 . The aluminum cup of claim 24 , wherein the taper angle of the frustoconical shape minimizes tearing of the cup side wall.
26 . An aluminum cup comprising:
a common aluminum material comprising:
an aluminum foil layer, comprising a common foil thickness of between 80 to 180 microns;
a first polymer layer disposed on a first surface of the aluminum foil layer; and
a second polymer layer disposed on a second surface of the aluminum foil layer opposite the first surface;
a cup side wall formed from the common aluminum material, the cup side wall comprising:
a first perpendicular edge; and
a second perpendicular edge,
wherein the first perpendicular edge of the cup side wall is bonded to the second perpendicular edge of the cup side wall to bond the first polymer layer to the second polymer layer to form the cup side wall in a frustoconical shape having a taper angle between about 3 degrees and about 12 degrees;
a rolled lip at an upper edge of the cup side wall; and
a cup bottom formed from the common aluminum material,
wherein the cup side wall is bonded to the cup bottom to bond the first polymer layer of the cup side wall to the first polymer layer of the cup bottom, and the cup side wall and the cup bottom have the same common foil thickness.